Physical Components of Secondary Pump System

Physical Components of Secondary Pump Condition-based Monitoring System

Katie Behnert

Physical Portion Digital Portion

Katie Behnert Abdullah Weiss

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OutlineSetting the StageTechniques UsedVibration AnalysisTemperature Analysis

ConclusionsFuture Work/

Additional Applications

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The National Bureau of Standards Reactor (NBSR) is a heavy

water reactor used for creating neutrons needed for research.

[https://www.ncnr.nist.gov/summerschool/ss07/bob_williams.pdf]

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Secondary pumps circulate regular water that cools the heavy

water leaving the reactor via external cooling towers.5

Condition-based Monitoring (CBM) is a

type of predictive maintenance that

looks at the pump’s current status.

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The designed CBM system consists of two techniques:

vibration and temperature analysis.

Vibration Analysis Temperature Analysis

[http://www.go4b.com/usa/datasheets/milli-temp-bearing-temperature-sensor.pdf]

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Vibration Analysis ExplanationHow it works

Vibration analysis data is recorded in the form of sine waves;

these waves are defined using amplitude and frequency.

[https://commons.wikimedia.org/w/index.php?curid=14994157][https://www.quora.com/What-is-the-amplitude-of-a-light-wave]

Complete Cycle

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Amplitude

The recorded data is graphed on a frequency plot, instead of a

time plot, because it is filtered using Fast Fourier Transform (FFT).

Time

Am

plitu

de

Am

plitu

de

Frequency

Time

Am

plitu

de

Am

plitu

de

Frequency

[http://www.hds.bme.hu/~fhegedus/VibrationMonitoring/Literature/Pump_Condition_Monitoring_Through_Vibration_Analysis_Cornelius_Scheffer_2008.pdf]

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[https://ham.stackexchange.com/questions/5052/losing-low-frequencies-in-am-transmission]

Am

plitu

de

Frequency[https://www.vibrationanalysis.co.uk/time-domain-plots.html]

Am

plitu

de

Time

The filtered data must be analyzed for it to be useful: this is

done by picking peaks at important frequencies.

= VPF

= Multiples

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Auto Spectrum of Vibration

Frequency (Hz)

Ampl

itude

)𝑉𝑉𝑉𝑉𝑉𝑉 = 𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂 𝑆𝑆𝑂𝑂𝑂𝑂𝑂𝑂𝑆𝑆 × (𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑂𝑂𝑂𝑂 𝑜𝑜𝑜𝑜 𝑉𝑉𝑂𝑂𝑂𝑂𝑂𝑂𝑉𝑉

The important peak(s) correspond to different faults that

could be affecting the pumps.

Unbalance

[https://www.pumpsandsystems.com/topics/pumps/centrifugal-pumps/][https://www.flowcontrolnetwork.com/the-importance-of-shaft-alignment/]

Misalignment

[https://www.nuclear-power.net/nuclear-engineering/fluid-dynamics/centrifugal-pumps/cavitation/suction-cavitation/]

CavitationLooseness

[http://www.rotor.zone/vibrationanalysis/styled-7/photos/index.html]

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The faults are identified by their spectra that consist of a

specific combination of peaks at certain frequencies.

[http://www.hds.bme.hu/~fhegedus/VibrationMonitoring/Literature/Pump_Condition_Monitoring_Through_Vibration_Analysis_Cornelius_Scheffer_2008.pdf]

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Misalignment

Frequency

Am

plitu

de

1x

2x 3x

Unbalance

Frequency

Am

plitu

de

1x

Cavitation

Frequency

Am

plitu

de

1x2x

Looseness

Frequency

Am

plitu

de

1x

1.5x

2x

2.5x 3x 4x 5x 6x0.

5x

The graphs of some faults look similar, so phase analysis is

employed to confirm the pump’s diagnosis.

[http://www.hds.bme.hu/~fhegedus/VibrationMonitoring/Literature/Pump_Condition_Monitoring_Through_Vibration_Analysis_Cornelius_Scheffer_2008.pdf]

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[https://commons.wikimedia.org/wiki/File:Phase_shift.png]

Reference Rover

Frequency

Am

plitu

de1x

2x

3x

Parallel Misalignment

Frequency

Am

plitu

de 1x

2x 3x

Angular Misalignment

Once possible faults are identified readings are taken, over time,

and compared to the machine’s known vibration signature.

[https://www.slideshare.net/makarandnikume/rt-2008-principles-and-practices-of-vibrational-analysis-keefer]

Amplitude

Frequency

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Vibration Analysis EquipmentPhysical Sensors

The vibration analysis system consists of accelerometers,

transmitter, and a Data Acquisition Device (DAQ).

Accelerometer

Transmitter

Data Acquisition Device

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Single Branch Vibration System

Connection18

Multi-branch Vibration System

Connection19

System Uncertainty: 6.4236%

Vibration Analysis ApplicationMounting the sensors & recording data

All of the sensors used get

mounted onto a secondary

pump, which is part of a

pump-motor setup.

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The vibration sensors

need to be mounted

along certain axes so that

their measurements can

be compared.

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Specific locations to mount the sensors onto must be

carefully chosen to follow strict criteria.

Surface Criteria

Relatively smooth

Clean

Wider than the sensor

Flat (for flat magnets)

Position Criteria

Close to the vibration source

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Sensor Mounting in the Axial Direction

Axial

Tangential

Radial

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Sensor Mounting in the Radial Direction25

Axial

Tangential

Radial

Sensor Mounting in the Tangential Direction26

Axial

Tangential

Radial

Temperature AnalysisOverview

Temperature analysis records temperature, over a long

period of time, to watch for any trends.

Temperature dependence on time

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Temperature inside the bearings is used because bearing

oil temperature increases as they wear.

[http://www.go4b.com/usa/datasheets/milli-temp-bearing-temperature-sensor.pdf]

[http://www.go4b.com/usa/datasheets/milli-temp-bearing-temperature-sensor.pdf]

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The temperature sensor is inserted into the grease zerk of

the bearing to take internal temperature readings.30

[http://www.go4b.com/usa/datasheets/milli-temp-bearing-temperature-sensor.pdf]

Temperature SensorOutside of Bearing

(Green Area)

The temperature analysis system consists of a temperature sensor,

called a Resistance Temperature Detector (RTD), and a DAQ.

Temperature Sensor

Data Acquisition Device

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Temperature System

Connection32

System Uncertainty: 1.3457%

Whole System Connection33

Auto Spectrum of Vibration

Frequency (Hz)

Ampl

itude

Mechanical Looseness

Cavitation

[http://www.hds.bme.hu/~fhegedus/VibrationMonitoring/Literature/Pump_Condition_Monitoring_Through_Vibration_Analysis_Cornelius_Scheffer_2008.pdf]

34 Conclusions

Frequency (Hz)

Ampl

itude

Frequency (Hz)

Ampl

itude

Future Work/ Additional Applications

Vibration analysis can be used in a variety of other

applications, such as crack detection in reactor vessels.

[https://www.indiamart.com/proddetail/reactor-vessel-3093578291.html]

[http://blog.onlinemetals.com/weldability-of-stainless-steel/]

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Future work includes

using FFT and auto

spectrum to filter

power data from

nuclear channels.

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Raw Data

FFT Data

Auto Spectrum

Frequency (Hz)

Acknowledgements

Muhammad Afridi, PhD

Richard Allen

ScottArneson

JulieBorchers, PhD

JosephDura, PhD

Heather Chen-Mayer, PhD

Sam MacDavid

MitchellStansloski, PhD, PE

DanyalTurkoglu, PhD

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Acknowledgements39

Special Thanks

Marcus Schwaderer, MBA, COR II, PM II

Dağistan Şahin, PhD Abdullah Weiss, EIT

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41 Questions